actually, i've spotted some isolated surfaces. tinytiny surfaces..





and Meshmixer indicates them as mesh defects(blue=hole, red=non-manifold):

Yeah it's probably those little surface fragments that Marco shows above.

Try this version, here I've removed those little tiny slivery pieces, hopefully it should generate a better mesh.

I exported an STL with it with Angle = 5, and Divide larger than = 1 applied to "All" and it doesn't seem to have any problems in it anymore.

I wish I knew which particular step was getting those little tiny fragments to be produced in the first place, I'd like for that not to happen...

- Michael

Hi Michael,
I don't remember exactly how I did that. I know I couldn't loft the tapered end and I don't think I used a sweep. I think used a revolve and then extruded the flange and then did a difference to put the hole in the flange and then did a combine ....

Thanks for your help guys ....



bz